Form piece for countertop back splash



April 18, 1961 H. E. HANSEN 2,98

FORM PIECE FOR COUNTERTOP BACK SPLASH Original Filed March 15, 1956 2 Sheets-Sheet 1 INVENT OR HERMAN E. HANSEN his ATTORNEYS April 18, 1961 H. E. HANSEN 2,980,477

FORM PIECE FOR COUNTERTOP BACK SPLASH Original Filed March 15, 1956 2 Sheets-Sheet 2 F/ae. W 0 3 W 1 3 /d6 /J? 74 F/G 7 was; \\iit\\\\i\\ INVENTOR- r HERMAN E. HANSEN B f /00 ,mm 171/1114 /04 his ATTORNEYS positions, vinyl' plastic coated felt base or the like.

2,980,477 FORM PIECE FOR COUNTERTOP BACK SPLASH Herman E. Hansen, Winterton, N.Y., assignor to Con- Sgzolellgrm-Nairn Inc., Kearny, N.J., a corporation of New Original application Mar. 15, 1956, Ser. No. 571,689,

ncw Patent No. 2,890,919, dated June 16, 1959. Digi fscgggnd this application Dec. 8, 1958, Ser. No.

2 Claims. or. 311-407 This invention relates to counters and to component parts useful in the construction thereof. This application is a division of co-pending application S.N. 571,689 filed March 15, 1956 for Counter Construction.

The demand for counters having surfaces which are durable, attractive, and easily maintained, has resulted in using more elaborate equipment. Presently, factoryfab ricated and site-fabricated units alike most often utilize externally applied polished metal moulding strips of the snap-on type to finish the raw edges. Although economical, external moulding strips represent a source of leakage which can loosen the adhesive bond securing the surfacing sheet and can rot the wooden substructure of a counter. Also, they tend to collect dirt at the line of junction with the surfacing sheet and, in many applications, form an undesirably conspicuous margin around the entire counter assembly. It has, of course, been recognized that metal edge moulding can be eliminated by utilizing some of the surfacing sheet material to cover the raw edge in what is commonly called a self edge. -A liquid-tight, durable self edge has not, however, been attainable heretofore except by the most costly techniques, and in site-fabricated units they are all but unattainable as a practical matter.

Accordingly, it is one object of the present invention to provide improved counter constructions having self edges of pleasingly rounded contour which are both liquidtight and'durable while at the same time capable of simplified fabrication.

Another object of the invention is to provide an improved counter construction, the sub-structure of which can comprise conventional, easily worked, wood panels, and the surfacing of which comprises durable, water-impervious sheet material uniquely integrated with the substructure to form a completed assembly in which unbroken extensions of the surfacing material define the edges.

Another object of the invention is to provide novel substructure form pieces for contouring a counter framework to receive surface sheeting.

In accordance with the present invention,=a series of form pieces for defining respectively the front or leading edge of the counter, the cove between the fiat working surface of the counter, and the upright back splash, and the top edge of the back splash, are provided for attachment to flat panels to become, together with the panels, part of a counter sub-structure defining a smooth, continuous surface to which a single piece of surfacing sheet ates atent material is adhesively attached to integrate the assembly and to provide, if desired, a water-impervious, attractive wear surface altogther free of breaks, cracks, or externally applied marginal mouldings.

The form piece which defines the front edge of the counter can be arranged for application to the horizontal panel in a simple snap fit, with the design being such that once in position and with the surfacing sheet applied, it defines an enlarged, gently rounded edge which is not susceptible of displacement either angularly or in translation. The cove forming piece is designed in accordance with the invention to form a junction between the horizontal and vertical panels and includes surfaces complementary to both panels. In one embodiment, the cove forming piece comprises not only a sub-structure for backing up the surfacing sheet but a bridging link by means of Representative embodiments of the invention are described below having reference to the accompanying drawings in which:

Figure 1 is a view in perspective of a counter assembly embodying the present invention; Figure 2 is a view in vertical assembly shown in Figure 1;

section of the counter Figure 3A is a view in perspective with its left hand end in vertical section of a short length of a form or contouring piece for use in fabricating the front edge of the counter;

Figure 3B is aview similar to Figure 3A showing a modified form piece for the front edge of the counter;

Figure4 is'a view similar to Figure 3A showing one.

design of form piece for defining the cove of the counter assembly, at the intersection of the counter and the back splash;

Figure 5A is a view similar to Figure 3A showing the form piece for completing the back splash of the counter and for defining a wall junction;

Figure 5B is a View similar to Figure 5A showing a modified form piece for completing the back splash of the counter and for defining a wall junction, the form piece being illustrated as mounted on a fragment of a back panel; I V g V Figure 6 is a fragmentary view in vertical section illustrating an alternative technique for forming the counter construction; and

Figure 7 is a fragmentary view in vertical section showing a modified form of the cove portion of the counter construction which is particularly useful in the drawings.

Referring to Figures 1 and 2, the counter of the present invention, generally indicated by the numeral 10 and shown for purposes of illustration as formed with a cut-out to receive a conventional sink ll, includes a main horizontal panel 12 which can be constructed of" Patented Apr. 18, 1961 It has particular utility in the construction 17 engage the forward edge of the panel and -the insimilar functions, need not be describedin detail. Attached to' the rear end portion of the panel His a.

plywood oranother suitablesubstructure mateiiall Sef below. This form piece, as well as the other form pieces hereinafter referred-tmare preferablyrhadebf'a strong 5 rigid material such as metal, and "the metal is preferably i of the eXtrudable'typ'such as aluminum having in' its finished form surfacestwhichare; slightly 'dull, e.g., a satin finishrc'apable of establishing'a strong adhesive bond to the overlying'surfacingsheet material of the finished counter. As shown' in Figures :2 and 3A, the front edge form: piece 14includ'es a continuously'curving' convex outer wall 1 5, the central inner portion of which is formed with a pair; of ribs 16 and;17 adapted tofabut the leadling edge of the panel 12 along vertically spaced apart lines. The upper portion of the wall 15, which overlies the panel 12, is formed with a slight reverse'curva j turej18 to define'a feather edge'19 at theline ofiHn'c- -tion with thepanel. The undersideof the feather edge 29 19is formed with a'flat 20 adapted tore'st on the panel' 12 and" rearward of the, flatltl'is a depending rih 21 adapted to rest on the panel 12 close to itsedge. The lower endof the contoured outer wall 15 terminates in an upwardly extending vertical flangev 22linturned at 25 23 to form an abutment to engage the; underside of the. panel 12. As best shownin Figurel the form piece 14 surrounds'the forward end of the panel12 so that the" feather edge 19811100121113! merges into the upper sur- 'face of the panel 12 along a line spaced inwardly'from the forward edge thereof with the flatZQ and 'rib Q1: engaging theupper surface. In addition, the;ribs 16 and turned edge 23 ofpthe flange 22 engages the lower surface of the panel along a marginalline spaced inwardly from the forward edge. Preferablythe formlpiece ;15 is 'so'constructed that it must be slightly expanded to fit, over the panel. edge, the expansion being accommof, dated by slight flexing of the resilientwall 15. In'this fashion, a tight, snap-on fit is assured. The design of the'uform iece, is such that most externally applied 7 forces tendto increase theffrictional binding or clamping forces which'help to hold it in positionjon the panel 12.". Togethe'rvwith' the adhesively applied sheet over- 1ay,1as' described below, the leading edge 'constructionrhecomes. fully secured against angular 'andtranslational.

' into a suitable groove .(not shown) which ispreferahlyf pre aformecl inl the leading edge of the panel v12,. -Parts generally similar to those'of Figure 3A are identified by 1ike primed referencechar-acters and, .having generally coveforming piece 28.- As shown in-Figure 4, theicove piece-28 can include a bodyportion 30 preferablyhollow and having a concavely curved exterior surface '32 and fiat under surfaces 34 and-36. which form feather edges at either extreme of the concavesurfacea Extending perpendicularly downward from the surface 36 is a flange 38. AsshoWn-in Figure 2, the covepiece 28 engages the rear end portion of the pane-112 with the flange-=38, flush: with the rear edge thereof and the .surface 36 abuttingthe upper; suIfaceJthereof so that the adjacent feather edge merges smoothlywith. the upper surface of the panelalong aline spaced inwardly from therear edge, v Q a 1 Secured in abutting relation to the, surface 3ft-of the; cove forming piece 28-is an upright back splash panel 40 which can he formedof any suitable material such. as plywood or the like. Fastening means such as nails 44cm lie-driven through theYlower end portiongof the backsplash panel and into the rear-"edge ofthe panel. 76

12 through the flange 38. m If necessary, the flange'38 of cured to the forward edge of the panel 12 is a conthe covepiece can be .apertured, as at 42 toreceive'the. toured front edge form piece 14 described more fully fastening means. r:

The upper edge of the back splash panel .40 has secured thereto a top edge form piece, difierent designs of which are illustrated by Fig j'rcsj5A and 5B. Referring first to Figuresl and 5A, there is shown atop edge form piece 50 including a convexly curved'exterior surface 52 terminating at its upper end in a horizontal, slightly sharpened flange 54' extendingrearwardlytherefrom which provides 'a continuation of the convex exterior surface.

' At its lower end the piece is formed with-aninturned' fia'nig'efor shoulder '56; which rests on the top edge corner ftheba pan 0; T e pi ce, =c9 p1 by 11 depending back fiange 57, internally shoulderedaLSSito rest on the othertop edge corner of the .back panel 40, and adapted topassTdownward 'alongth'e back wall of the panel flush therewith. As shown in Figure 2, the back splash topforming piece S'Ois 's'ecuredfin'po'siition ,by

securing means such as nails 59 passing through theflange 57 to enter the panel 40. The cOnveXerterioI- surface 52 of the form piece forms aeominuatien-or the forward surface of the panel with the horizontal flange" 54 extending beyond the rearward f surface thereofj to be received, after the'sheet ;-'s;urram inate'rial is -applied, in [suitable groove scored in the"wall -W agairist which the soiintef e y at as-- l if t is f hisa a er f junction reams; A

As shownby Figure 5B, thetop edge 'form 'piece 60 7 can be modified by the'additioniif; a ibarbedjiiinerflange 62 eds e gi m a h vlde 64 n s ar ed t b re ceived inagroove 66 formed'inrthe upper edge ofthe bacliisplash panel, afragme nt of which ijs identified the m al 407-5 1 f 'Pi fill l b, -e u e vegrly curved wail'70 terminating at its lower; fQrward end inn-surface to rest' 'on the forward corner edge of the baclgsplash panel 40. and: terminating at its rearward, ra end in a hq iza i engaging an tendin g: downward frorn the underside of the wall 70 is a flange 74, the free 'end of which rests on the baclgcorner edge of the back splash] panel ,40'. e 7

t n hus be n t the as m l d P n l ,2 and 40 "or 40" with the three form pieces 1,4, 281and 50 or 60 attached theretopprovide a smooth, continuous exterior surface which extends fromthe-front edge ofthe; counter to the top of the back splash. -As stated,preferablyeach h m t v ed w herexte j t amn ia. e

otthepi 'ltI d-50 i e m i allvire pcnd ur lar flat surfaces of the two panels 112i andjll 'isi a single imr-s-r he? t ck he t f mrs ri iamete nq as ala -t p: t e f el he tm tsrial,

p te h r exibl un er nd ml andifiq i a d we t e rmn orexa r ept a t b e anati ed with a vinyl plastic or it can take the formjpf a solid plastic hee iaive i P a i m r r all v t e s t s. h sheetma fi s 'h e etabli aerated 1 9 i? e 9 t a lvo s n t ee etwee i and s supportingsurfaces, ihi 'position, be understobd that the" eet-76 r rtsa ldit afal s r' a t ihiaa e f sw y-J pa iq lamhe et s i a' n gw r qn i a rm Pi e .14 a t a o lm yen f eff between the exterior counter surface and the underside of the sheet, preferably by'applying the adhesive separately to both surfaces. After the adhesive has been aplied the sheet is brought into registry with the substructure and pressed into position, using, for example, the matrix or tool of said copending application to bring the sheet and sub-structure into intimate relationship throughout, the single sheet thereby being bonded to the exposed surfaces of the several panel and form pieces alike.

Another example of a material which can be utilized in conjunction with the present invention, is the so-called C-stage plastic materials of the type comprising laminated sheets, such as, for example, paper woven fabric and matter or Wovens glass fibers impregnated with any suitable thermosetting resin such as phenol urea melamine formaldehyde resins and their derivates including the group of unsaturated polyester resins, e.g., ethylene glycolmaleate acid, polymer modified with monomeric styrene. Such plastics are commercially available as Formica which is the trade mark of a product of the Formica Company of Cincinnati, Ohio, Micarta which is the trade mark of a product of the Westinghouse Electric and Manufacturing Company of Pittsuburgh, Pennsylvania, or Farlite which is the trade mark of a product of Farley and Loetscher of Dubuque, Iowa.

In general, the C-stage plastic laminates cannot be bent to conform with a counter surface such as presently disclosed without the application of heat. Accordingly, where such plastics are utilized it is desirable to pre-form the sheet into the shape of the exterior surface of the counter. After the C-stage plastic sheet has been preformed, suitable adhesives of the type mentioned above are then applied in the same manner as previously indicated. The sheet is then engaged to the counter surface and the matrix applied and clamped in the manner indicated before.

Referring now to Figures 6 and 7, an alternative fabricating technique and a modified cove forming piece are illustrated. A back splash panel 88 can, as preliminary step in the fabrication of the counter, first be disposed in the plane of the horizontal planel 90 and spaced edgewise therefrom for a predetermined distance to receive a flat, unbent sheet 92 of surfacing material, adhesive being applied between the opposed surfaces. After the adhesive has set, the back splash panel 88 is swung into a plane normal to that of the panel 90 by flexing the bridging strip of the sheet material into a generally rounded curvature to define the cove. Next, a reinforced form piece 94 is inserted behind the sheet material at the cove and is secured to both the horizontal and vertical panels. The form piece 94 includes a concavely rounded center wall 96 terminating at its respective ends in reinforced mutually perpendicular shoulders 98 and 101) which abut the edges of the panels 88 and 90, respectively. Marginal flanges 102 and 104 can be formed at the ends of the shoulders 98 and 100 respectively to overlie the panels 88 and 90 and to set the position of the form piece 94 so its curved surface 96 precisely backs up the sheet material 92 at the cove. A barbed flange 106 can be formed on the shoulder 100 to be driven into a suitable channel or groove 108 formed in the horizontal panel 90, after which suitable securing means 110 such as nails, screws, or the like, can be driven into the edge or side, as the case may be, of the back panel 88. It will be seen, therefore, that the form piece 94 serves as both a cove defining member and as a structural link between the two panels.

It can thus be seen that there has been provided a counter which may be easily constructed without the need of expensive tools or machines. Of particular significance is the fact that the counter presents a smooth, continuous, water impervious surface, thereby eliminating the need for exposed moulding strips. As noted above, the use of such exposed moulding strips presents the disadvantage of dirt collection and leakage so that with the counter of the present invention, these disadvantages are efiectively overcome. It should also be noted that the rearwardly extending horizontal flange 54 of the back splash form piece provides an effective means whereby the counter may be installed against a wall so as to insure aleak-proof fit. It is well known that most walls are not precisely flat and include undulations, dips and the like. Heretofore, it has been found necessary to either shape the back splash panel of the counter to the wall or provide caulking between the space between the wall and the back splash panel, which procedures have obvious disadvantages. With the present invention, the counter is initially placed against the wall so that the end of the flange 54 engages the same. The wall is then scored or grooved along the flanged and this scoring is repeated until a horizontal groove is formed in the wall which is suitable to receive the flange with the rear surface of the back splash panel abutting the wall. In this manner, there is provided a horizontal surface which intersects the wall, the horizontal surface being impervious to water and shaped to direct the water downwardly away from the wall. 7

It will be appreciated that various modifications can be made in the invention as described above without in any way deviating from the scope thereof as defined in the appended claims.

I claim:

1. In a counter construction, a back splash panel having an upper substantially horizontal edge, a form piece mounted on the upper edge of said panel, said form piece presenting an exterior surface forming a continuation of the forward surface of said panel and curving convexly upwardly and rearwardly, said form piece further including a horizontal flange forming a continuation of said convexly curved surface and projecting rearwardly beyond the rearward surface of said panel and a shoulder resting on the upper edge of said panel, means to secure the form piece to said panel and a thin sheet of material intimately bonded to the forward surface of said panel and the exterior surface of said form piece.

2. In a counter construction, a back splash panel having an upper substantially horizontal edge, a form piece mounted on the upper edge of said panel, said form piece presenting an exterior surface forming a continuation of the forward surface of said panel and curving convexly upwardly and rearwardly, said form piece further including a horizontal flange forming a continuation of said convexly curved surface and projecting rearwardly beyond the rearward surface of said panel, a depending flange extending downwardly behind said back splash panel, means to secure the depending flange to the panel and a shoulder resting on the rear upper edge of the panel, and a thin sheet of material intimately bonded to the forward surface of said panel and the exterior surface of said form piece.

References Cited in the file of this patent UNITED STATES PATENTS 2,594,516 Swisher Apr. 29, 1952 2,614,014 Stanitz Oct. 14, 1952 2,626,846 Morris Jan. 27, 1953 2,665,182 Stanitz Jan. 5, 1954 2,665,183 Battles Jan. 5, 1954 2,702,221 Hammer Feb. 15, 1955 2,721,333 Stanitz Oct. 25, 1955 2,783,111 Hammer Feb. 26, 1957 2,845,666 Knapp Aug. 5, 1958 

